Latchbolt damping module

ABSTRACT

An exemplary damper module is configured for use with a latchbolt assembly, and generally includes a mounting bracket, a first slowing mechanism, and a second slowing mechanism. The latchbolt assembly generally includes a drive member, a latchbolt, and a retractor connected between the drive member and the latchbolt. Each of the slowing mechanisms is independently operable to slow the extension speed of the latchbolt. The first slowing mechanism includes a rack gear and a rotary damper including a pinion gear. The rack gear is configured to be mounted to the drive member, and the rotary damper is mounted to the mounting bracket. The second slowing mechanism includes a slowing arm and a biasing member engaged with the slowing arm. The slowing arm is movably mounted to the mounting bracket and is configured to engage the retractor.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 16/027,529 filed Jul. 5, 2018 and issued as U.S. Pat. No.11,156,025, the contents of which are incorporated herein by referencein their entirety.

TECHNICAL FIELD

The present disclosure generally relates to the reduction of the noisegenerated during the operation of door hardware, and more particularlybut not exclusively relates to systems and methods for reducing theamount of noise generated during the operation of exit devices.

BACKGROUND

Acoustic noise is becoming a growing concern in many differentenvironments, including theaters, auditoriums, schools, libraries, andhealthcare settings. Noise is of particular concern in healthcaresettings, such as hospitals, nursing homes, and mental healthfacilities. In healthcare settings, a loud environment can affect thesleep of patients, which can be detrimental to their recovery times.Noise is often one of the lowest scoring items on patient surveys, whichcan lead to lower reimbursements to the medical facility. In addition todisturbing patients, noise can also be distracting or bothersome to themedical staff, and may lead to loss of focus and errors.

In many settings, door hardware can be a significant factor contributingto undesirable environmental noise. When a person enters or exits a roomthrough a door, the hardware can make loud and distracting sounds.Building codes and other regulatory requirements often dictate thatcertain doors be equipped with exit devices, which can be louder thancertain other types of door hardware. While many manufacturers have madeefforts to reduce the noise generated by their devices, certainconventional exit devices nonetheless generate noise in excess of themaximum recommended levels set forth in industry guidelines.

It has been found that a significant factor contributing to noisegeneration is the free return of the latchbolt from its retractedposition to its extended position. During this latching movement, thecomponents of the exit device may impact or grind against one another,which may lead to undesirable noise generation. During relatchingoperations (i.e., where the latchbolt extends to engage the strike)impact and other contact between the latchbolt and the strike can alsocontribute to noise generation.

As is evident from the foregoing, certain conventional exit devicesgenerate more noise than is desirable in many environments, particularlyas the latchbolt moves toward its extended position. For these reasonsamong others, there remains a need for further improvements in thistechnological field.

SUMMARY

An exemplary damper module is configured for use with a latchboltassembly, and generally includes a mounting bracket, a first slowingmechanism, and a second slowing mechanism. The latchbolt assemblygenerally includes a drive member, a latchbolt, and a retractorconnected between the drive member and the latchbolt. Each of theslowing mechanisms is independently operable to slow the extension speedof the latchbolt. The first slowing mechanism includes a rack gear and arotary damper including a pinion gear. The rack gear is configured to bemounted to the drive member, and the rotary damper is mounted to themounting bracket. The second slowing mechanism includes a slowing armand a biasing member engaged with the slowing arm. The slowing arm ismovably mounted to the mounting bracket and is configured to engage theretractor. Further embodiments, forms, features, and aspects of thepresent application shall become apparent from the description andfigures provided herewith.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is an illustration of an exit device installed to a door.

FIG. 2 is a cross-sectional illustration of the exit device.

FIG. 3 is a cross-sectional illustration of a portion of the exitdevice.

FIG. 4 is a perspective view of a latch control assembly of the exitdevice.

FIGS. 5A, 5B and 5C respectively illustrate a portion of the exit devicewith a latchbolt in a retracted position, an extended position, and apartially-retracted position.

FIG. 6 is an exploded assembly view of a damper module according tocertain embodiments.

FIG. 7 is a perspective view of the damper module illustrated in FIG. 6.

FIG. 8 is a perspective illustration of a rotary damper that may beincluded in the damper module illustrated in FIGS. 6 and 7 .

FIG. 9 is a cross-sectional illustration of the rotary damperillustrated in FIG. 8 .

FIG. 10 is a perspective view of the damper module illustrated in FIGS.6 and 7 as installed to the exit device illustrated in FIGS. 1-4 .

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Although the concepts of the present disclosure are susceptible tovarious modifications and alternative forms, specific embodiments havebeen shown by way of example in the drawings and will be describedherein in detail. It should be understood, however, that there is nointent to limit the concepts of the present disclosure to the particularforms disclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives consistent with the presentdisclosure and the appended claims.

References in the specification to “one embodiment,” “an embodiment,”“an illustrative embodiment,” etc., indicate that the embodimentdescribed may include a particular feature, structure, orcharacteristic, but every embodiment may or may not necessarily includethat particular feature, structure, or characteristic. Moreover, suchphrases are not necessarily referring to the same embodiment. It shouldfurther be appreciated that although reference to a “preferred”component or feature may indicate the desirability of a particularcomponent or feature with respect to an embodiment, the disclosure isnot so limiting with respect to other embodiments, which may omit such acomponent or feature. Further, when a particular feature, structure, orcharacteristic is described in connection with an embodiment, it issubmitted that it is within the knowledge of one skilled in the art toimplement such feature, structure, or characteristic in connection withother embodiments whether or not explicitly described.

Additionally, it should be appreciated that items included in a list inthe form of “at least one of A, B, and C” can mean (A); (B); (C); (A andB); (B and C); (A and C); or (A, B, and C). Similarly, items listed inthe form of “at least one of A, B, or C” can mean (A); (B); (C); (A andB); (B and C); (A and C); or (A, B, and C). Further, with respect to theclaims, the use of words and phrases such as “a,” “an,” “at least one,”and/or “at least one portion” should not be interpreted so as to belimiting to only one such element unless specifically stated to thecontrary, and the use of phrases such as “at least a portion” and/or “aportion” should be interpreted as encompassing both embodimentsincluding only a portion of such element and embodiments including theentirety of such element unless specifically stated to the contrary.

The disclosed embodiments may, in some cases, be implemented inhardware, firmware, software, or a combination thereof. The disclosedembodiments may also be implemented as instructions carried by or storedon one or more transitory or non-transitory machine-readable (e.g.,computer-readable) storage media, which may be read and executed by oneor more processors. A machine-readable storage medium may be embodied asany storage device, mechanism, or other physical structure for storingor transmitting information in a form readable by a machine (e.g., avolatile or non-volatile memory, a media disc, or other media device).

In the drawings, some structural or method features may be shown inspecific arrangements and/or orderings. However, it should beappreciated that such specific arrangements and/or orderings may not berequired. Rather, in some embodiments, such features may be arranged ina different manner and/or order than shown in the illustrative figuresunless indicated to the contrary. Additionally, the inclusion of astructural or method feature in a particular figure is not meant toimply that such feature is required in all embodiments and, in someembodiments, may not be included or may be combined with other features.

As used herein, the terms “longitudinal,” “lateral,” and “transverse”are used to denote motion or spacing along three mutually perpendicularaxes. In the coordinate system illustrated in FIGS. 1 and 2 , the X-axisdefines the longitudinal directions, the Y-axis defines first and secondtransverse directions, and the Z-axis defines first and second lateraldirections. Additionally, the longitudinal directions may alternativelybe referred to as the proximal direction (to the right in FIG. 2 ) andthe distal direction (to the left in FIG. 2 ). These terms are used forease and convenience of description, and are without regard to theorientation of the system with respect to the environment. For example,descriptions that reference a longitudinal direction may be equallyapplicable to a vertical direction, a horizontal direction, or anoff-axis orientation with respect to the environment.

Furthermore, motion or spacing along a direction defined by one of theaxes need not preclude motion or spacing along a direction defined byanother of the axes. For example, elements which are described as being“laterally offset” from one another may also be offset in thelongitudinal and/or transverse directions, or may be aligned in thelongitudinal and/or transverse directions. The terms are therefore notto be construed as limiting the scope of the subject matter describedherein.

Referring now to FIG. 1 , illustrated therein is a closure assembly 80including a frame 82 and a swinging door 84 pivotally mounted to theframe 82. The door 84 has an interior side face 85 and an oppositeexterior side face. The door 84 is mounted to the frame 82 by a set ofhinges such that a pushing force on the interior side face 85 urges thedoor 84 to swing outwardly in an opening direction. An exit device 100is mounted to the interior side face 85 of the door 84, and isconfigured to interact with a strike 90 to selectively retain the door84 in a closed position relative to the frame 82. While other forms arecontemplated, the illustrated strike 90 is mounted to the interior sideof the frame 82, and includes a roller 92.

With additional reference to FIGS. 2 and 3 , the exit device 100includes a pushbar assembly 101 which may also be referred to as anactuation assembly or actuating assembly. The pushbar assembly 101includes a mounting assembly 110 configured for mounting to the door 84,a drive assembly 120 including a pushbar module 130, and a latch controlassembly 140 operably connected with the drive assembly 120. The exitdevice 100 further includes a latching module 150 that includes alatchbolt 152, and which is operably connected with the latch controlassembly 140. The pushbar module 130 is operable to transition the driveassembly 120 from a deactuated state to an actuated state when manuallyactuated by a user. Actuation of the drive assembly 120 causes acorresponding actuation of the latch control assembly 140, therebymoving the latching module 150 to a retracted position. With thelatching module 150 in the retracted position, the latchbolt 152 iscapable of clearing the strike 90 such that the door 84 can be movedfrom the closed position. As described herein, the exit device 100 iscapable of a plurality of operational movements, one or more of whichinvolves retraction and/or extension of the latchbolt 152.

The mounting assembly 110 generally includes an elongated channel member111, a base plate 112 mounted in the channel member 111, and a pair ofbell crank mounting brackets 114 coupled to the base plate 112. Thechannel member 111 extends in the longitudinal (X) direction, has awidth in the transverse (Y) direction, and has a depth in the lateral(Z) direction. Each of the mounting brackets 114 includes a pair oftransversely spaced walls that extend laterally away from the base plate112. The illustrated mounting assembly 110 also includes a header plate113 positioned adjacent a proximal end of the channel member 111, and aheader casing 117 mounted to the header plate 113. The mounting assembly110 also includes a header bracket 118 that is mounted to the headerplate 113 within the header casing 117. As illustrated in FIGS. 4 and 5, the ceiling of the header bracket 118 includes a first guide slot 116,and each sidewall of the header bracket 118 includes a second guide slot119.

The drive assembly 120 includes the pushbar module 130, a drive bar 122connected between the pushbar module 130 and the latch control assembly140, and a return spring 126 engaged with the drive bar 122 and themounting assembly 110. The return spring 126 biases the drive bar 122 ina distal extending direction, thereby biasing the drive assembly 120toward its deactuated state. As described herein, the drive assembly 120is operationally connected with the latch control assembly 140 via afirst lost motion connection 128, which may include a spring 129 biasingthe latch control assembly 140 toward its deactuated state.

The pushbar mechanism 130 generally includes a manually actuated pushbar132, a pair of pushbar brackets 134 coupled to the underside the pushbar132, and a pair of bell cranks 136 operably connecting the pushbar 132with the drive bar 122. Each bell crank 136 is pivotably mounted to acorresponding one of the bell crank mounting brackets 114, and includesa first arm pivotably connected to a corresponding one of the pushbarbrackets 134 and a second arm pivotably connected to the drive bar 122.The pivotal connections may, for example, be provided by pivot pins 103.The pushbar 132 is laterally movable between an extended or deactuatedposition and a depressed or actuated position, and the bell cranks 136translate lateral movement of the pushbar 132 to longitudinal movementof the drive bar 122.

With additional reference to FIG. 4 , the latch control assembly 140generally includes a longitudinally-sliding control link 141 connectedwith the latching module 150, a fork link 142 connected between thecontrol link 141 and the drive assembly 120, and a drive pin 143 mountedto a proximal end portion of the control link 141 and extending throughthe guide slot 119 of the header bracket 118. The illustrated latchcontrol assembly 140 further includes a pair of laterally-slidingconnector links 146 and a pair of pivot cranks 147. The pivot cranks 147connect the control link 141 with the connector links 146, and translatelongitudinal movement of the control link 141 to lateral movement of theconnector links 144. As described herein, the latch control assembly 140is operationally connected with the latching module 150 via a secondlost motion connection 148, and a spring 149 biases the latching module150 toward its deactuated state.

The control link 141, the pin 143, the connector links 146, the pivotcranks 147, and the fork link 142 may alternatively be referred to ascontrol components 140′ of the latch control assembly 140. Each of thecontrol components 140′ has an extended position and a retractedposition, and a corresponding extending direction and retractingdirection. Each control component 140′ is configured to move in itsretracting direction (i.e., toward its retracted position) in responseto actuation of the drive assembly 120, and is operable to move in itsextending direction (i.e., toward its extended position) in response todeactuation of the drive assembly 120. As will be appreciated, theextending and retracting directions for one component 140′ may bedifferent from the extending and retracting directions for anothercomponent 140′. By way of example, the extending and retractingdirections for the control link 141 and the fork link 142 arelongitudinal directions, the extending and retracting directions for theconnector links 146 are lateral directions, and the extending andretracting directions for the pivot cranks 147 are rotationaldirections.

The latching module 150 includes the latchbolt 152, which is pivotablymounted to the header bracket 118 by another pivot pin 106 such that thelatchbolt 152 pivots between an extended latching position and aretracted unlatching position. The latching module 150 also includes aretractor 154, which is pivotably coupled with the latchbolt 152 via apivot pin 153. The retractor 154 is also operationally coupled to thecontrol link 141 via the second lost motion connection 148, andpartially defines the second lost motion connection 148. Moreparticularly, the retractor 154 includes an elongated opening 155through which the pin 143 extends, thereby forming the second lostmotion connection 148 between the control link 141 and the retractor154. The retractor 154 also includes an extension 156, which projectsthrough the first guide slot 116.

While the illustrated latching mechanism 150 includes a latchbolt 152that is mounted in the header case 117, it is also contemplated that thelatching mechanism 150 may take another form. For example, the exitdevice 100 may include one or more remote latching mechanisms inaddition to or in lieu of the illustrated latching mechanism 150. Suchremote latching mechanisms may, for example, be provided as a top latchmechanism configured to engage the top jamb of a door frame, and/or as abottom latch mechanism configured to engage the floor. The remotelatching mechanisms may be connected to the connector links 146 via aconnector, such as a rod or a cable. In such forms, movement of theconnector links 146 in a laterally inward retracting direction (i.e.,toward one another) may serve to actuate the remote latching mechanisms.

In the illustrated embodiment, the control components 140′ areoperationally coupled with one another for joint movement between theextended and retracted positions thereof. As a result, movement of oneof the control components 140′ causes a corresponding movement of theremaining components 140′, and increasing or decreasing the movementspeed of one of the components 140′ causes a corresponding increase ordecrease in the movement speed of the remaining components 140′.Additionally, the latchbolt 152 and the retractor 154 are operationallycoupled with one another for joint movement between the extended andretracted positions thereof, and are operationally coupled with thelatch control assembly 140 via the second lost motion connection 148.

An opening/closing cycle of the closure assembly 80 may be considered tobegin with the door 84 in its closed position and the exit device 100 inits deactuated state. In this state, the drive assembly 120 and thelatch control assembly 140 are in the deactuated states thereof, and thelatchbolt 152 is extended and engaged with the strike 90, therebypreventing opening of the door 84. In this state, a user may depress thepushbar 132 to actuate the exit device 100 and retract the latchbolt152. More specifically, depressing the pushbar 132 actuates the driveassembly 120, thereby moving the drive bar 122 distally toward theretracted position thereof. This distal movement of the drive bar 122 istransmitted to the fork link 142 via the first lost motion connection128, thereby actuating the latch control assembly 140 and retracting thelatchbolt 152. This operational movement may be referred to herein asthe actuating operational movement, following which the door 84 can beopened.

After opening the door 84, the user may release the pushbar 132 toinitiate a deactuating operational movement. Upon release of the pushbar132, the internal biasing mechanisms of the exit device 100 return thedrive assembly 120 to its deactuated state. More specifically, thereturn spring 126 moves the drive bar 122 proximally toward its extendedstate, thereby causing the bell cranks 136 to drive the pushbar 132 toits projected position.

With additional reference to FIGS. 5A, 5B and 5C, the proximal movementof the drive bar 122 initiates a latching operational movement, whichinvolves deactuation of the latch control assembly 140 and the latchingmodule 150. This operational movement begins with the latch controlassembly 140 in its actuated state and the latching module 150 in itsretracted position (FIG. 5A). As the drive bar 122 moves proximally, thespring 129 of the first lost motion connection 128 urges the fork link142 in the proximal direction, thereby deactuating the latch controlassembly 140 and moving the control components 140′ to the deactuatedpositions thereof (FIG. 5B). As the control link 141 and the pin 143move in the proximal direction, the spring 149 drives the retractor 154to return the latching module 150 to its extended position (FIG. 5B).

As the door 84 reaches its partially-closed position, the strike 90engages the latchbolt 152 and drives the latching module 150 to anintermediate or partially retracted position (FIG. 5C) against thebiasing of the spring 149. As a result of the second lost motionconnection 148, however, this movement of the latching module 150 doesnot necessarily drive the pin 143 from its deactuated position.Accordingly, the latch control assembly 140 may remain in its deactuatedstate during closing of the door 84.

As the door 84 moves from its partially-closed position to itsfully-closed position, a relatching operational movement is initiated.Movement of the door 84 from its partially-closed position to itsfully-closed position causes the latchbolt 152 to clear the roller 92 ofthe strike 90. Once the roller 92 is cleared, the return spring 149drives the retractor 154 proximally to return the latching mechanism 150to its extended or deactuated position.

It has been found that certain of the above-described operationalmovements may result in the generation of noise that can beobjectionable in certain circumstances. During the latching operationalmovement, for example, the control components 140′ may slide against orimpact one another or other components of the exit device 100, such asthe mounting assembly 110, the drive assembly 120, and/or the latchingmechanism 150. Similarly, during the relatching operational movement,the latching mechanism 150 may slide against or impact other componentsof the closure assembly 80, such as the latch control assembly 140and/or the strike 90. However, the exit device 100 is provided with oneor more noise reduction mechanisms that reduce the generation of thisnoise.

With reference to FIGS. 6 and 7 , illustrated therein is a noisereduction mechanism in the form of a damper module 200, which isconfigured for use in exit devices such as the exit device 100illustrated in FIGS. 1-5 . In the illustrated form, the damper module200 is configured as a modular subassembly that can easily be installedto or removed from the exit device 100 by maintenance personnel. Inother embodiments, various components of the damper module 200 may beincorporated into the exit device 100 prior to installation, for exampleat the time of manufacture.

The damper module 200 is configured to reduce the amount of noisegenerated during at least the latching and relatching operations byslowing the deactuating speeds of the latch control assembly 140 and thelatching mechanism 150. The damper module 200 generally includes amounting bracket 210, a cover or housing 220 mounted to the mountingbracket 210, a rotational damper 230 mounted to the mounting bracket 210and housed in the housing 220, a rack member 250 slidably mounted to thehousing 220 and engaged with a pinion gear 240 of the rotational damper230, and a slowing arm 260 movably mounted to the mounting bracket 210.

As described herein, the damper module 200 is configured to slow theextension speed of various components of the exit device 100, therebyslowing the extension speed of the latchbolt 152. More particularly, therotary damper 230 and the rack member 250 cooperate to slow theextension speed of the drive pin 143, thereby slowing the extensionspeed of the retractor 154 and the latchbolt 152. Additionally, theslowing arm 260 engages the retractor extension 156 to independentlyslow the extension speed of the retractor 154, thereby further slowingthe extension speed of the latchbolt 152. Accordingly, the damper module200 may alternatively be referred to herein as a latchbolt slowingmodule 200, the rotary damper 230 and rack member 250 may collectivelybe referred to herein as a first slowing mechanism 201, and the slowingarm 260 and the biasing members 206 may collectively be referred toherein as a second slowing mechanism 202.

The mounting bracket 210 is configured for mounting to the headerbracket 118, and generally includes a laterally-extending first bracketportion 211 and a second bracket portion 212 extending transversely fromthe first bracket portion 211. The first bracket portion 211 includes apair of pockets 216 for receiving springs 206, which are engaged withthe slowing arm 260 and urge the arm 260 in the distal (X⁻) direction.Formed on a distal end of the first bracket portion 211 is a mountingplate 218 that facilitates attachment of the mounting bracket 210 to theexit device 100. The second bracket portion 212 includes a recess 213 inwhich a base plate 231 of the rotary damper 230 is seated, and whichincludes a pair of projections 214 that aid in rotationally coupling thebase plate 231 with the mounting bracket 210. The mounting bracket 210further includes a plurality of mounting apertures 219 that aid insecuring the housing 220 to the mounting bracket 210, for example viafasteners 209.

Like the mounting bracket 210, the housing 220 includes alaterally-extending first housing portion 221 and a second housingportion 222 extending transversely from the first housing portion 221.The first housing portion 221 includes a slot 226 which, when the dampermodule 200 is mounted to the header bracket 118, is aligned with thefirst guide slot 116 and is operable to receive the extension 156 of theretractor 154. The second housing portion 222 includes a gradated recesssized and shaped to house the rotary damper 230 when the base plate 231thereof is seated in the recess 213 of the mounting bracket 210. Morespecifically, the gradated recess includes a first recessed portion 223operable to receive a body portion 232 of the damper 230 and a secondrecessed portion 224 operable to receive the pinion gear 240. The secondhousing portion 222 further includes a channel 225 that is operable toslidably receive a portion of the rack member 250, and which includes alongitudinal guide slot 227 operable to slidably receive a guideprojection 257 of the rack member 250.

With additional reference to FIGS. 8 and 9 , the rotary damper 230generally includes a base plate 231, a stator 232 mounted to themounting bracket 210, a rotor 234 rotationally mounted to the stator232. In the illustrated form, the stator 232 defines a chamber 233, andthe rotor 234 is mounted within the chamber 233. In other forms, thechamber 233 may be defined within the rotor 234, and the stator 232, maybe mounted within the chamber 233. The base plate 231 includes a pair ofnotches 204 that interface with the projections 214 and facilitaterotational coupling of the stator 232 with the mounting bracket 210. Therotary damper 230 further includes a cap 236 that encloses the chamber233. The rotor 234 is mounted in the chamber 233, and includes a stem235 that extends through an opening in the cap 236. The cap 236cooperates with the stator 232 and the rotor 234 to form a fluid-tightseal for the chamber 233. The sealed chamber 233 is filled with ahydraulic fluid 237 that generates a resistive torque in response torotation of the rotor 234 relative to the stator 232, such as siliconeoil. The stem 235 is engaged with a shaft 238 via a one-way clutch 239that couples the stem 235 and shaft 238 for joint rotation in onerotational direction while allowing relative rotation of the stem 235and shaft 238 in the opposite rotational direction. The pinion gear 240is mounted to the shaft 238 such that the gear 240 is engaged with therotor 234 via the one-way clutch 239.

The rack member 250 generally includes a gear rack 252 that is engagedwith the teeth 242 of the pinion gear 240, and which is formed on a bodyportion 254 of the rack member 250. The rack member 250 further includesa receiving recess 253 sized and shaped to receive an end portion of thedrive pin 143, and a shoulder portion 255 in which the receiving recess253 is formed. Projecting from the body portion 254 adjacent the gearrack 252 is a guide projection 257, which is received in the guide slot227 to guide the rack member 250 for sliding movement in thelongitudinal directions.

The slowing arm 260 generally includes a central arm portion 262, a pairof tabs 264 formed on opposite sides of the arm portion 262, and afinger 266 projecting from the arm portion 262 in the same direction asthe tabs 264. The tabs 264 and the springs 206 are received in thepockets 216 of the mounting bracket 210 such that the springs 206 urgethe slowing arm 260 in the distal direction (i.e., toward the mountingplate 218). When installed to the exit device 100, the finger 266projects toward and/or into the first guide slot 116 and is operable toengage the extension 156 of the retractor 154.

FIG. 10 illustrates the damper module 200 installed to the exit device100. In the interest of more clearly illustrating the internalcomponents of the damper module, the housing 220 is depicted in phantomin FIG. 10 . With the damper module 200 installed, the mounting bracket210 is seated on the header bracket 118, and is secured to the mountingassembly 110 by a pair of screws that pass through the mounting plate218.

The housing 220 is secured to the mounting bracket 210 via the screws209 such that the housing 220 at least partially covers the movingcomponents of the damper module 200. For example, the first housingportion 221 at least partially covers the slowing arm 260, and thesecond housing portion 222 at least partially covers the rotary damper230 and the rack member 250. More specifically, the recessed portions223, 224 at least partially cover the rotary damper 230, and the wallsof the channel 225 at least partially cover the rack member 250.Additionally, the channel 225 is generally aligned with one of the guideslots 119 formed in the header bracket 118.

The rotary damper 230 is captured between the mounting bracket 210 andthe housing 220. As a result, the stator 232 is rotationally coupledwith the mounting bracket 210 and the rotor 234 and pinion gear 240 arecapable of joint rotation relative to the stator 232.

The rack member 250 is slidably mounted in the channel 225, and one endof the rack member 250 is mounted to the drive pin 143. Morespecifically, an end portion of the drive pin 143 is seated in thereceiving recess 253 such that the shoulder portion 255 is supported bythe drive pin 143. With the body portion 254 supported by the floor ofthe channel 225 and the shoulder portion 255 captured between the drivepin 143 and lip of the channel 225, the rack member 250 is constrainedto movement in the longitudinal directions in which the drive pin 143travels. Additionally, with the guide projection 257 received in theguide slot 227, the guide components 227, 257 cooperate to aid inlimiting the travel of the rack member 250 in the longitudinal (X)directions.

The slowing arm 260 is positioned adjacent the ceiling of the headerbracket 118, and the finger 266 extends into the guide slot 116 andincreases the surface area at which the extension 156 can contact theslowing arm 260. Additionally, the tabs 264 and the biasing members 206are seated in the pockets 216 such that the slowing arm 260 is biasedtoward the retractor extension 156. Thus, the biasing members 206 biasthe slowing arm 260 in the retracting direction of the extension 156 andresist movement of the slowing arm 260 in the extending direction of theextension. In the illustrated form, the biasing members 206 are providedin the form of springs 206. In other embodiments, the biasing members206 may be provided in another form, such as unidirectional lineardampers.

With the damper module 200 installed, operation of the exit device 100may proceed along the lines set forth above. During actuation of theexit device 100, the drive pin 143 moves in a distal actuating directionfrom its deactuated position (FIG. 5B) to its actuated position (FIG.5A). This movement of the drive pin 143 causes relative movement of therack member 250 and the pinion gear 240, thereby causing the rack member250 to drive the pinion gear 240 in an actuating rotational direction.The configuration of the one-way clutch 239 is selected such that thisrotation of the pinion gear 240 is not transmitted to the rotor 234. Asa result, a resistive torque is not generated by the rotary damper 230,and the actuating movement of the latch control assembly 140 is notmaterially altered by the first slowing mechanism 201.

As a result of the actuating movement of the drive pin 143, theretractor 154 and the extension 156 thereof are likewise driven fromtheir deactuated positions (FIG. 5B) to their actuated positions (FIG.5A). This movement of the retractor 154 enables the biasing members 206to drive the slowing arm 260 in the distal direction such that the tabs264 engage end walls of the pockets 216. Due to the fact that the secondslowing mechanism 202 does not resist the actuating movement of theretractor 154, the actuating movement of the latching mechanism 150 isnot adversely affected by the second slowing mechanism 202.

During deactuation of the exit device 100, the drive pin 143 moves in aproximal deactuating direction from its actuated position (FIG. 5A) toits deactuated position (FIG. 5B). This movement of the drive pin 143causes relative movement of the rack member 250 and the pinion gear 240,thereby causing the rack member 250 to drive the pinion gear in adeactuating rotational direction. The configuration of the one-wayclutch 239 is selected such that this rotation of the pinion gear 240 istransmitted to the rotor 234. As a result, the rotary damper 230generates a resistive torque that resists rotation of the pinion gear240 in the deactuating direction. This resistance is transmitted to thedrive pin 143 via the rack member 250, thereby slowing the deactuatingmovement of the latch control assembly 140 and the extension speed ofthe latching mechanism 150.

During deactuating movement of the drive pin 143, the return spring 149drives the retractor 154 and the extension 156 thereof from theiractuated positions (FIG. 5A) to their deactuated positions (FIG. 5B). Asthe retractor 154 moves toward its deactuated position, the extension156 travels along the guide slot 116 and engages the slowing arm 260. Toreduce the noise generated as a result of this impact, the slowing arm260 may be formed of or coated with a vibration-damping material.Additionally or alternatively, a damping pad may be mounted to theportions of the arm 262 and/or the finger 266 that are impacted by theextension 156. With the extension 156 in contact with the slowing arm260, further movement of the retractor 154 in its deactuating directionis resisted by the biasing members 206. As a result, the second slowingmechanism 202 further slows the extending or deactuating speed of thelatching mechanism 150.

As is evident from the foregoing, the slowing mechanisms 201, 202independently slow the deactuating speed of the latch control assembly140 and the latching mechanism 150 during the latching operationalmovement. More particularly, the first slowing mechanism 201 slows thedeactuating speed of the latch control assembly 140 by slowing themovement of the drive pin 143, which also causes a corresponding slowingof the deactuating speed of the latching mechanism 150. Additionally,the second slowing mechanism 202 independently slows the deactuatingspeed of the latching mechanism 150 by providing an additionalresistance that slows the deactuating speed of the retractor 154.Furthermore, while the slowing mechanisms 201, 202 provide for slowingof the deactuating speeds of the latch control assembly 140 and latchingmechanism 150, neither slowing mechanism 201, 202 provides materialresistance to the actuation of those components. As a result, the amountof force that must be exerted by a user in order to retract thelatchbolt 154 is not adversely affected.

During the relatching operational movement, the second slowing mechanism202 functions in a manner substantially similar to that described above.As the latchbolt 152 is driven from its extended position (FIG. 5B) toits partially-retracted position (FIG. 5C) under the urging of theroller 92 of the strike 90, the retractor 154 and the extension 156thereof are likewise driven from their deactuated positions toward theiractuated positions. This movement of the retractor 154 enables thebiasing members 206 to drive the slowing arm 260 in the distal directionsuch that the tabs 264 engage end walls of the pockets 216. Due to thefact that the second slowing mechanism 202 does not resist this movementof the retractor 154, the amount of force that must be imparted by thestrike roller 92 in order to drive the latchbolt 152 to itspartially-retracted position is not increased.

As the latchbolt 152 clears the strike roller 92, the return spring 149drives the retractor 154 to move the latchbolt 152 toward its extendedposition. As the retractor 154 and the extension 156 move from theirpartially-retracted positions (FIG. 5C) to their actuated positions(FIG. 5B), the extension 156 travels along the guide slot 116 andengages the slowing arm 260. With the extension 156 in contact with theslowing arm 260, further movement of the retractor 154 in itsdeactuating direction is resisted by the biasing members 206. As aresult, the second slowing mechanism 202 slows the extending ordeactuating speed of the latching mechanism 150 during the relatchingoperational movement.

As is evident from the foregoing, the damping module 200 is capable ofslowing the deactuating or extending speeds of various components of theexit device 100. Those skilled in the art will readily appreciate thatthis slowing of the extension speeds can reduce the amount of noisegenerated during the operation of the exit device 100. For example,slowing the deactuating speed of the latch control assembly 140 canreduce vibrations and noise resulting from metal-to-metal contact, suchas sliding, grinding, or impact vibrations and noises. Slowing theextension speed of the latchbolt 154 itself can similarly reducevibrations resulting from contact between internal components of theexit device 100, as well as vibrations resulting from contact betweenthe latchbolt 154 and the strike 90. Thus, in slowing the deactuatingspeeds of various components of the exit device 100, the damper module200 may facilitate quieter operation of the exit device 100,particularly during latching and relatching operations.

Although the damping module 200 has been illustrated and described asbeing configured for use with a rim-type exit device 100 (i.e., one inwhich a single latching mechanism 150 is mounted to the pushbar assembly101), it is also contemplated that the damping module 200 may be used incombination with other forms of exit devices, such as those includingremote latching mechanisms. Such exit devices typically include one ormore latching mechanisms that are positioned remotely from the pushbarassembly 101 (e.g., at the top and/or the bottom of the door 84), andwhich are connected to the pushbar assembly 101 via vertical connectors.

In vertical exit devices, the connectors may be surface-mounted (i.e.,mounted to the interior side face 85 of the door 84), or may beconcealed (i.e., mounted in channels formed within the door 84), andtypically take the form of rods or cables. Regardless of the form, theconnectors are typically connected to the connector links 146 of thelatch control assembly 140 such that actuation of the drive assembly 120causes a corresponding actuation of the remote latching mechanisms. Whenso connected, the remote latching mechanism and the latch controlassembly 140 actuate and deactuate in unison with one another. Thus, inslowing the deactuation speed of the latch control assembly 140, thedamper module 200 is capable of slowing the deactuating speeds of theremote latching mechanisms.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly the preferred embodiments have been shown and described and thatall changes and modifications that come within the spirit of theinventions are desired to be protected. It should be understood thatwhile the use of words such as preferable, preferably, preferred or morepreferred utilized in the description above indicate that the feature sodescribed may be more desirable, it nonetheless may not be necessary andembodiments lacking the same may be contemplated as within the scope ofthe invention, the scope being defined by the claims that follow. Inreading the claims, it is intended that when words such as “a,” “an,”“at least one,” or “at least one portion” are used there is no intentionto limit the claim to only one item unless specifically stated to thecontrary in the claim. When the language “at least a portion” and/or “aportion” is used the item can include a portion and/or the entire itemunless specifically stated to the contrary.

What is claimed is:
 1. A system, comprising: an actuation assembly; adrive member operably connected with the actuation assembly anddisplaced by the actuation assembly in a drive member actuatingdirection and in a drive member deactuating direction; a retractoroperably connected with the drive member and displaceable in a retractoractuating direction in response to movement of the drive member in thedrive member actuating direction, and displaceable in a retractordeactuating direction in response to movement of the drive member in thedrive member deactuating direction; a latchbolt operably connected withthe retractor and having an extended position and a retracted position,wherein the latchbolt is configured to move toward the retractedposition in response to movement of the retractor in the retractoractuating direction, and wherein the latchbolt is configured to movetoward the extended position in response to movement of the retractor inthe retractor deactuating direction; a first slowing module operable toslow movement of the drive member in the drive member deactuatingdirection and to slow movement of the retractor in the retractordeactuating direction, and thereby slowing movement of the latchbolttoward the extended position; and a second slowing module operable toslow movement of the retractor in the retractor deactuating direction,and thereby further slowing movement of the latchbolt toward theextended position; and wherein the first slowing module includes gearingand a damper configured to slow movement of the gearing in a lineardirection during movement of the latchbolt toward the extended position;and wherein the gearing is constrained to relative movement in thelinear direction, and wherein the second slowing module is alsoconstrained to movement in the linear direction.
 2. The system of claim1, wherein the second slowing module is operable to slow movement of theretractor in the retractor deactuating direction independently of thefirst slowing module.
 3. The system of claim 1, wherein the gearingcomprises a gear rack and a pinion gear engaged with the gear rack. 4.The system of claim 3, wherein the damper is configured to slow movementof the gear rack and the pinion gear in the linear direction duringmovement of the latchbolt toward the extended position; and wherein thegear rack and the pinion gear are constrained to relative movement inthe linear direction; and wherein the second slowing module comprises aslowing arm that is constrained to movement in the linear direction. 5.The system of claim 3, wherein the gear rack is mounted to the drivemember.
 6. The system of claim 3, wherein the damper is a rotary damperincluding a rotor and a stator, wherein the pinion gear is mounted tothe rotor.
 7. The system of claim 6, wherein the rotary damper furthercomprises a one-way clutch connected between the rotor and the piniongear.
 8. The system of claim 7, wherein the one-way clutch is configuredto rotationally decouple the rotor and the pinion gear for relativerotation as the gear rack drives the pinion gear in a first rotationaldirection corresponding to the drive member actuating direction, andwherein the one-way clutch is configured to rotationally couple therotor and the pinion gear for joint rotation as the gear rack drives thepinion gear in a second rotational direction corresponding to the drivemember deactuating direction.
 9. The system of claim 1, wherein thedamper comprises a rotary damper.
 10. The system of claim 1, wherein thedamper is a unidirectional damper.
 11. The system of claim 10, whereinthe unidirectional damper is configured to slow movement of the gearingduring movement of the latchbolt toward the extended position withoutslowing movement of the gearing during movement of the latchbolt towardthe retracted position.
 12. The system of claim 1, wherein the secondslowing module comprises a slowing arm and a biasing member biasing theslowing arm in a first slowing arm direction corresponding to theretractor actuating direction and resisting movement of the slowing armin a second slowing arm direction corresponding to the retractordeactuating direction.
 13. A method of slowing an extension speed of alatchbolt assembly, wherein the latchbolt assembly includes a latchbolt,a retractor having a latchbolt-extending motion and alatchbolt-retracting motion, and a drive member having aretractor-extending motion and a retractor-retracting motion, the methodcomprising: slowing the retractor-extending motion of the drive memberby: gearing coupled to the drive member; and a damper engaged with thegearing such that the damper resists relative movement of the gearing ina first linear direction; wherein the retractor-extending motion of thedrive member causes relative movement of the gearing in the first lineardirection of relative movement such that the damper resists the relativemovement of the gearing, thereby slowing the retractor-extending motionof the drive member; and slowing the latchbolt-extending motion of theretractor by: a slowing member; and a biasing member operable to resistmovement of the slowing member in a first slowing direction and biasingthe slowing member in a second slowing direction opposite the firstslowing direction; wherein the latchbolt-extending motion of theretractor causes the retractor to drive the slowing member in the firstslowing direction such that the biasing member resists movement of theslowing member, thereby slowing the latchbolt-extending motion of theretractor; and wherein the movement of the gearing is constrained tomovement in the first linear direction, and wherein the slowing memberis also constrained to movement in the first linear direction.
 14. Themethod of claim 13, wherein slowing of the retractor-extending motion ofthe drive member using the gearing and the damper is independent of theslowing of the latchbolt-extending motion of the retractor using theslowing member and the biasing member.
 15. The method of claim 13,wherein the gearing comprises a gear rack and a pinion gear engaged withthe gear rack.
 16. The method of claim 13, wherein the gearing comprisesa first gear member mounted to the drive member, and a second gearmember meshing with the first gear member; and wherein theretractor-extending movement of the drive member causes relativemovement of the first gear member and the second gear member in thefirst direction of relative movement such that the damper resists therelative movement of the first gear member and the second gear member,thereby slowing the retractor-extending motion of the drive member. 17.The method of claim 16, wherein one of the first gear member or thesecond gear member comprises a pinion gear, wherein the other of thefirst gear member or the second gear member comprises a rack gear, andwherein the first direction of relative movement includes a firstrotational direction of the pinion gear.
 18. The method of claim 17,wherein the damper comprises a rotary damper configured to slow rotationof the pinion gear in the first rotational direction.
 19. The method ofclaim 13, wherein the gearing comprises a first gear engaged with asecond gear, and wherein the damper comprises a rotatory damperconfigured to slow rotation of one of the first gear or the second gear.20. The method of claim 13, wherein the damper is a unidirectionaldamper such that the damper does not inhibit relative movement of thegearing in a second linear direction opposite the first lineardirection.